The Eagle Group realized early on the value of 3D scanning for manufacturing. Eagle CNC, Eagle Precision and Eagle Alloy all utilize 3D scanning systems that optimize our capabilities not just for inspection, but also for reverse engineering and prototyping. For us, scanning is an integral part of the casting process.
That’s why Eagle Alloy has upgraded its Keyence scanner several times to stay ahead of the curve. Our latest model, the WM-6000, helps our shell-mold foundry deliver even more precise, reliable castings for our customers.
Many manufacturers still use manual measuring tools like calipers, air gauges and go/no-go gauges. In fact, Eagle Group companies use them as well—in certain cases. However, we have largely moved to 3D scanning since it offers a faster, more accurate and more comprehensive approach to capturing dimensional data. Especially for large or complex geometries that are difficult to measure by hand, 3D scanning is not only faster but also much more precise. The wide-ranging benefits of 3D scanning can be grouped into a few key categories, each contributing to heightened efficiency throughout the manufacturing journey.
3D scanning dramatically reduces inspection time by capturing tens of millions of data points almost instantly, providing a complete view of an object’s surface geometry, no matter how large or complex the part.
This technology has streamlined our quality control process, allowing us to identify issues faster and maintain dimensional precision. The result? A more efficient workflow and a dependable supply of high-quality, on-time parts for our customers.
What 3D scanning offers is microscopic-level accuracy. For complex parts destined for demanding field applications, the micron-level analysis can make all the difference in creating parts that perform as expected through thousands of use cycles.
Each scan is fast and highly repeatable, allowing us to inspect more parts in less time while maintaining consistent accuracy. This efficiency strengthens our quality control efforts, making it easier to detect tolerance deviations and ensure every part meets exacting standards.
The scanner’s proprietary software gathers tens of millions of data points into a digital mesh that our operators use to compare against target measurements and to gage part conformity. New scanners like the WM-6000 also allow data to be easily exported and shared. And new features offer augmented capabilities, like texture overlays, for an even more realistic rendering of the mold or casting. Having this data in an easily readable format means we can share scans with other departments and with customers, a process that provides transparency and wards off potential issues before we begin full production.
We’ve previously explored the powerful inspection capabilities of 3D scanning. For a deeper dive into the value 3D scanning adds to the casting process, be sure to check out that article. Since then, advancements in scanning technology have taken things even further. In the next section, we’ll highlight how the latest model—the WM-6000—delivers new advantages over its predecessors.
The WM-6000 uses three synchronized cameras that work together to enable easy and comprehensive scanning. One of these cameras is installed in a handheld instrument, allowing the operator to circle around the part to gather data points. While our previous scanner was a tabletop version that worked only with limited dimensions, our technicians can now easily scan large and complex parts, capturing accurate measurements with increased flexibility. Once a part is scanned, real-time scanning confirmation ensures full coverage and instant feedback, helping to eliminate guesswork and reduce the need for rescans.
Another notable enhancement is the integration of a built-in violet laser, which enables smooth and reliable scanning across a wide range of surfaces, including challenging materials that scatter or absorb traditional laser light. Additionally, surface condition checking provides immediate insight into part finish and integrity, helping to detect imperfections early in the process.
Altogether, these upgrades make the new scanner not only more powerful but also more user-friendly, allowing our teams to perform high-precision inspections faster and with greater consistency. All of this means better quality control and more reliable production outcomes for our customers.
Eagle Alloy engineer Marvin Cisneros utilizing the Keyence WM-3000 3D scanner
The Keyence WM-6000 improves our ability to analyze part quality by ensuring that every part meets the highest standards of precision. The ability to scan in real time with immediate feedback on-screen removes much of the guesswork involved in the measurement process, potentially avoiding problems later down the line from incomplete or erroneous measurement. This streamlined approach not only speeds up production but also drastically reduces the chances of human error, resulting in cast parts that consistently meet the most rigorous of our customers’ specifications.
Outside of inspection, 3D scanning has a range of design benefits. We sometimes get an order that doesn’t come with blueprints or a CAD model, but starts simply with an existing part. A 3D scan allows us to reverse engineer dimensions entirely from scratch. The process begins with a comprehensive scan that captures every part of its geometry, from its curves, edges and contours to its surface features. From there, we build a CAD model that mirrors the scanned geometry, comparing the model against the scan data to ensure alignment with the customer’s expectations.
The same reverse-engineering principles can be applied to create replacement parts for our own in-house equipment. Sometimes our shop equipment requires replacement parts that are either discontinued or hard to obtain, and our team can scan the original component and generate a digital model. That scan serves as the foundation for casting the replacement parts we require. Replicating replacement parts in this way leads to minimal equipment downtime, ensuring on-time delivery for our customers.
While we primarily use the WM-6000 for production, we can also apply it to tooling to prevent and diagnose issues we see throughout a run. For example, a 3D scan can reveal things like warping (especially in older tooling) that may lead to excess material at the parting line. In one recent case, a flatness reading revealed warping in an older tooling: armed with the scan data, we were able to eliminate the warping by mounting the old pattern onto new plates.
Whether for parts or tooling, inspection or reverse-engineering, the WM-6000’s ability to export comprehensive scan data is a game-changer for customer communication. By sharing detailed 3D models and dimensional reports, we’re providing full transparency on part conformity. This process builds trust and streamlines collaboration, helping customers confirm specs, and make faster, more informed decisions before full production begins.
At Eagle Alloy, investing in the Keyence WM-6000 isn't just about upgrading our tools—it’s about elevating the entire casting process. From drastically improving measurement accuracy and inspection speed to enhancing collaboration through data transparency, the WM-6000 empowers us to deliver higher-quality parts with greater efficiency. It’s more than a quality control tool; it’s a cornerstone of our commitment to continuous improvement.